Microporous films having zoned breathability

ABSTRACT

Breathable microporous films are provided having controlled regional breathability with high WVTR regions and thicker low WVTR regions. The zoned breathable microporous films are be made by selectively applying adhesive to the microporous film.

FIELD OF THE INVENTION

The present invention relates to absorbent articles incorporatingbreathable microporous films. More particularly, the present inventionrelates to breathable microporous films having zoned breathability andmethods of making the same.

BACKGROUND OF THE INVENTION

Various types of garments are presently available for absorbing humandischarge. Examples of these garments include baby diapers, femininecare products, incontinence garments and the like. Generally speaking,the basic structure of this class of garments requires an aqueous liquidpervious body-side liner, an absorbent pad ail containing one or morelayers for receiving and absorbing the discharge, and an aqueous liquidimpervious backing member for containing the discharge. Such garmentsusually include a film material that serves as an aqueous liquidimpervious outer cover. However, such film material lacks breathability,causing the undergarments to be hot and uncomfortable.

Microporous films are “breathable” barriers in the sense that the filmacts as a barrier to aqueous liquids and particulate matter but allowswater vapor and air to pass therethrough. In addition, by achieving andmaintaining high breathability it is possible to provide an article thatis more comfortable to wear since the migration of water vapor throughthe fabric helps reduce and/or limit discomfort resulting from excessmoisture trapped against the skin. Thus, such an article can potentiallycontribute to an overall improved skin wellness.

Accordingly, microporous films have become an important article ofcommerce, finding a wide variety of applications. For example,microporous films have been used as outer covers for personal careproducts such as diapers, training pants, incontinence garments,feminine hygiene products and the like. In addition, microporous filmshave likewise found use in protective apparel and infection controlproducts such as surgical gowns, surgical drapes, protective workwear,wound dressings and bandages. Often microporous films are utilized as amultilayer laminate. The films can provide the desired barrierproperties to the article while other materials laminated thereto canprovide additional characteristics such as strength, abrasion resistanceand/or softness and drapability. For example, fibrous webs such asnon-woven fabrics allow the laminate to retain its breathability and canprovide additional strength as well as an article having a cloth-likefeel. Thus, microporous film laminates can be used in a variety ofapplications including, for example, those described above.

Although the breathability provided by microporous films and/orlaminates thereof is advantageous in many articles, there exist somesituations where high breathability can be undesirable. For example, inabsorbent personal care articles such as diapers or incontinencegarments designed to absorb and contain aqueous liquid human exudatesthe breathable barrier and absorbent core generally work together toretain bodily fluids discharged into the garment. However, when fluid(aqueous liquid) is retained within the absorbent core significantlyhigher amounts of water vapor begin to pass through the breathablebarrier. The increased amounts of water vapor passing through the outercover can form condensate on the outer portion of the garment. Thecondensate is simply water but can be perceived by the wearer asleakage. In addition, the condensate can create a damp uncomfortablefeel to the outer portion of the garment which is unpleasant for thosehandling the article. It is believed that the skin wellness and/orimproved comfort benefits of breathable outer covers are not achieved atareas directly adjacent the portion of the absorbent core retainingconsiderable mounts of aqueous liquid (e.g. typically those areas of thecentral or crotch region of he garment). Providing a breathable barrierwhich has less or limited breathability in such regions, while providinggood breathability in the remaining regions, would provide a garmentwith excellent wearer comfort yet which limits the potential for outercover dampness. Thus, a breathable barrier that provides either zoned orcontrolled regional breathability is highly desirable.

Therefore, there exists a need for a breathable microporous film havingregions with varied levels of breathability. In addition, there exists aneed for such films which retain the desired barrier properties andwhich are capable of lamination to additional materials. Further, thereexists a need for methods of making such films and in particular methodsof reliably obtaining the desired levels of breathability in distinctregions of a film.

Thus, it becomes apparent that a need exists for an absorbentundergarment, diaper training pants or the like, that exhibits desiredabsorbency and containment characteristics of absorbent garments, suchas undergarments, while improving comfort during use.

SUMMARY OF THE INVENTION

The aforesaid needs are fulfilled and the problems experienced by thoseskilled in the art overcome by the film of the present invention which,in one aspect, comprises a first microporous region having a thicknessless than 100μ and a WVTR of at least 800 g/m²/24 hours and a secondregion having a WVTR (also referred to as porosity) less than that ofthe first region wherein the WVTR of the second region is at least 15%less than the WVTR of the first region. The film has a hydrohead of atleast about 50 mbar. The second region desirably has minimum dimensionsof 5 cm by 5 cm and still more desirably comprises from about 5% toabout 75% of the area of said film. In a further aspect, the firstregion can have a WVTR in excess of about 2500 g/m²/24 hours and thesecond region a WVTR less than about 1500 g/m²/24 hours. Additionallyand/or alternatively, the second region can have a WVTR at least about50% less than the WVTR of the first region. Further, the film cancomprise a third region having a WVTR intermediate to that of the firstand second regions. Still further, the film can comprise primarily athermoplastic polymer and in a further aspect, can comprise at leastabout 40% by weight filler and a thermoplastic polymer.

In a further aspect of the invention, the methods of making films havingregions of varied breathability are provided and can comprise providinga microporous film having a hydrohead of at least 50 mbars and a WVTR ofat least 800 g/m²/24 hours and then selectively applying adhesives to aselected portion of said film thereby creating first and second regionstherein. The WVTR is decreased within the second region of themicroporous film, i.e. the selected portion to which meaningfuladhesives have been applied, relative to the WVTR of the first region.The second region can have minimum dimensions of at least 5 cm by 5 cmand desirably the second region comprises from about 5% to about 75% ofthe area of said film. In a preferred embodiment, adhesive isselectively applied to the microporous film such that a pattern,continuous or discontinuous, of the second region is produced on thefilm.

Further aspects of the present invention will appear in the descriptionhereinafter.

DEFINITIONS

As used herein the term “nonwoven” fabric or web means a web having astructure of individual fibers or threads which are interlaid, but notin an identifiable manner as in a knitted or woven fabric. Nonwovenfabrics or webs have been formed by many processes such as for example,meltblowing processes, spunbonding processes, hydroentangling, air-laidand bonded carded web processes.

As used herein the term “spunbond fibers” refers to small diameterfibers of molecularly oriented polymeric material. Spunbond fibers maybe formed by extruding molten thermoplastic material as filaments from aplurality of fine, usually circular capillaries of a spinneret with thediameter of the extruded filaments then being rapidly reduced as by, forexample, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No.3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki etal., U.S. Pat. Nos. 338,992 and 3,341,394 to Kinney, U.S. Pat. No.3,502,763 to Hartman, U.S. Pat. No. 3,542,615 to Dobo et al, U.S. Pat.No. 5,382,400 to Pike et al., and U.S. Pat. No. 5,759,926 to Pike et al.Spunbond fibers are generally not tacky when they are deposited onto acollecting surface and are generally continuous.

As used herein the term “meltblown fibers” means fibers of polymericmaterial which are generally formed by extruding a molten thermoplasticmaterial through a plurality of fine, usually circular, die capillariesas molten threads or filaments into converging high velocity, usuallyhot, gas (e.g. air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter. Thereafter, themeltblown fibers can be carried by the high velocity gas stream and aredeposited on a collecting surface to form a web of randomly dispersedmeltblown fibers. Such a process is disclosed, for example, in U.S. Pat.No. 3,849,241 to Butin et al. Meltblown fibers may be continuous ordiscontinuous, are generally smaller than 10 microns in averagediameter, and are generally tacky when deposited onto a collectingsurface.

As used herein “multilayer nonwoven laminate” means a laminate of two ormore nonwoven layers such as, for example, wherein some of the layersare spunbond and some meltblown such as aspunbond/meltblown/spunbond(SMS) laminate. Examples of multilayernonwoven laminates are disclosed in U.S. Pat. No. 4,041,203 to Brock etal., U.S. Pat. No. 5,178,931 to Perkins et al. and U.S. Pat. No.5,188,885 to Timmons et al. Such a laminate may be made by sequentiallydepositing onto a moving forming belt first a spunbond fabric layer,then a meltblown fabric layer and last another spunbond layer and thenbonding the laminate such as by thermal point bonding as describedbelow. Alternatively, the fabric layers may be made individually,collected in rolls, and combined in a separate bonding step.

As used herein, the term “machine direction” or MD means the length of afabric in the direction in which it is produced. The term “cross machinedirection” or CD means the width of fabric, i.e. a direction generallyperpendicular to the MD.

As used herein the term “polymer” generally includes but is not limitedto, homopolymers, copolymers, such as for example, block, graft, randomand alternating copolymers, terpolymers, etc. and blends andmodifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” includes all possible spatial configurationsof the molecule. These configurations include, but are not limited toisotactic, syndiotactic and random symmetries.

As used herein, “ultrasonic bonding” means a process performed, forexample, by passing the fabric between a sonic horn and anvil roll asillustrated in U.S. Pat. No. 4,374,888 to Bornslaeger.

As used herein “point bonding” means bonding one or more layers offabric at numerous small, discrete bond points. For example, thermalpoint bonding generally involves passing one or more layers to be bondedbetween heated rolls such as, for example an engraved pattern roll and asmooth calender roll. The engraved roll is patterned in some way so thatthe entire fabric is not bonded over its entire surface, and the anvilroll is usually flat. As a result, various patterns for engraved rollshave been developed for functional as well as aesthetic reasons. Oneexample of a pattern has points and is the Hansen Pennings or “H&P”pattern with about a 30% bond area when new and with about 200bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen et al.

As used herein, the term “barrier” means a film, laminate or otherfabric which is relatively impervious to the transmission of aqueousliquids and which has a hydrohead of at least about 50 mbar. Hydroheadas used herein refers to a measure of the aqueous liquid barrierproperties of a fabric measured in millibars (mbar) as described hereinbelow. However, it should be noted that in many applications of barrierfabrics, it may be desirable that they have a hydrohead value greaterthan about 80 mbar, 150 mbar or even 200 mbar.

As used herein, the term “breathability” refers to the water vaportransmission rate (WVTR) of an area of fabric which is measured in gramsof water per square meter per 24 hours (g/m²/24 hours). The WVTR of afabric is the water vapor transmission rate which, in one aspect, givesan indication of how comfortable a fabric would be to wear. WVTR can bemeasured as indicated below and the results are reported in grams/squaremeter/24 hours.

As used herein the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which additives have beenadded. As used herein the term “multicomponent fibers” refers to fiberswhich have been formed from at least two polymers extruded from separateextruders but spun together to form one fiber. Multicomponent fibers arealso sometimes referred to as conjugate or bicomponent fibers. Thepolymers of a multicomponent fiber are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thefiber and extend continuously along the length of the fiber. Theconfiguration of such a fiber may be, for example, a sheath/corearrangement wherein one polymer is surrounded by another or may be aside by side arrangement, a pie arrangement or an “islands-in-the-sea”type arrangement. Multicomponent fibers are taught in U.S. Pat. No.5,108,820 to Kaneko et al., U.S. Pat. No. 4,795,668 to Krueger et al.and U.S. Pat. No. 5,336,552 to Strack et al. Conjugate fibers andmethods of making them are also taught in U.S. Pat. No. 5,382,400 toPike et al. and may be used to produce crimp in the fibers by using thedifferential crystallization properties of the two (or more) polymers.The fibers may also have various shapes such as those described in U.S.Pat. Nos. 5,277,976 to Hogle et al., U.S. Pat. No. 5,466,410 to Hillsand 5,069,970 and 5,057,368 to Largman et al.

As used herein the term “blend” means a mixture of two or more polymerswhile the term “alloy” means a sub-class of blends wherein thecomponents are immiscible but have been compatibilized.

As used herein the term “biconstituent fibers” or “multiconstituent”refers to fibers which have been formed from at least two polymersextruded from the same extruder as a blend. The term “blend” is definedabove. Biconstituent fibers do not have the various polymer componentsarranged in relatively constantly positioned distinct zones across thecross-sectional area of the fiber and the various polymers are usuallynot continuous along the entire length of the fiber, instead usuallyforming fibrils or protofibrils which start and end at random.Bicomponent and biconstituent fibers are discussed in U.S. Pat. No.5,294,482 to Gessner and in the textbook Polymer Blends and Compositesby John A. Manson and Leslie H. Sperling, copyright 1976 by PlenumPress, a division of Plenum Publishing Corporation of New York, ISBN0-306-30831-2, at pages 273 through 277.

As used herein, the term “scrim” means a lightweight fabric used as abacking material. Scrims are often used as the base fabric for coated orlaminated products.

As used herein, the term “garment” means the same as the term “personalcare product”.

As used herein, the term “infection control product” means medicallyoriented items such as surgical gowns and drapes, face masks, headcoverings like bouffant caps, surgical caps and hoods, footwear likeshoe coverings, boot covers and slippers, wound dressings, bandages,sterilization wraps, wipers, garments like lab coats, coveralls, apronsand jackets, patient bedding, stretcher and bassinet sheets and thelike.

As used herein, the term “personal care product” means personal hygieneoriented items such as diapers, training pants, absorbent underpants,adult incontinence products, feminine hygiene products, and the like.

As used herein the term “backsheet” refers to the aqueous liquidimpervious protective layer on the garment side of a personal careproduct which prevents bodily exudates from escaping from the product.

As used herein, the term “protective cover” means a cover for vehiclessuch as cars, trucks, boats, airplanes, motorcycles, bicycles, golfcarts, etc., covers for equipment often left outdoors like grills, yardand garden equipment (mowers, roto-tillers, etc.) and lawn furniture, aswell as floor coverings, table cloths, picnic area covers, tents and thelike.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is a schematic representation of an exemplary adhesiveapplicator assembly suitable for use in practicing the present inventionand a zone treated film made therefrom;

FIG. 1b is a schematic representation of an exemplary adhesiveapplicator assembly suitable for use in practicing the present inventionand a zone treated film made therefrom;

FIG. 2a is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 2b is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 3a is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 3b is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 4a is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 4b is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 5a is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 5b is a plan view of a zone treated microporous film suitable foruse in a practicing the present invention;

FIG. 6 a schematic representation of an adhesive application patternsuitable for use in practicing the present invention;

FIG. 7 is a schematic representation of an adhesive application patternsuitable for use in practicing the present invention;

FIG. 8 is a plan view of a zone treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 9 is a plan view of a zone treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 10 is a plan view of a zone treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 11 is a plan view of a zone treated microporous film suitable foruse in practicing the present invention and placement of an absorbentpad thereon;

FIG. 12 is a plan view representation of a treated microporous filmleaving an open adhesive pattern with minimal effect on the WVTR of thefilm;

FIG. 13 is a plan view representation of a treated microporous filmhaving an adhesive coat layer with significant reduction of the WVTR ofthe film;

FIG. 14 is a plan view representation of a treated microporous filmhaving an adhesive coat layer with significant reduction of the WVTR ofthe film;

DETAILED DESCRIPTION OF THE INVENTION

A breathable microporous film 412 can be treated, in accord with thepresent invention, to create a breathable film which can be used as abacksheet for personal care products, having regions of variedbreathability using adhesives or other coating materials. The term“adhesive” or “adhesives” as used herein includes, but is not limitedto, any material which will adhere to the microporous film when appliedby some coating apparatus, thereby reducing the WVTR of the microporousfilm where the adhesive has been applied. In reference to FIGS. 1a and 1b microporous film 412 is unwound from supply roll 414. A adhesiveapplicator 416 delivering an open patterned application, including butnot limited to a Nordson Control Coat CC-200 available from the NordsonCorporation at Norcross, Ga., applies a construction adhesive layer 418to the body-side surface 420 of the microporous film 412. Theconstruction adhesive layer 418 is applied in an open pattern and assuch, has minimal effect on the breathability of the microporous film412. A second adhesive applicator 422, including but not limited to aNordson EP45 contact type coating head available from the NordsonCorporation at Norcross, Ga., is pulsed to apply an adhesive coat layer424 on to areas where less breathability is desired. The amount ofadhesive applied in the adhesive coat layer 424 depends on the desiredreduction in breathability. The adhesive coat layer 424 applied to themicroporous film 412 at least partially covers or fills the pores withinthe microporous film 412, thereby reducing the size or number of poreswithin microporous film 412 thereby reducing the breathability of thefilm in these selected areas. Thus, a breathable microporous film 412can be made having regions of controlled breathability. As shown inFIGS. 2a and 2 b a microporous film 412 is created having a firstbreathable regions 426 and second regions 428 having a breathability orWVTR lower than that of the first regions 426. The treated film 412 canthen be wound on a winder roll 430 or further processed or converted asdesired.

The construction adhesive layer 418 can be applied over the entirebody-side surface 420 of the microporous film 412 or the constructionadhesive layer 418 can be applied in the areas only where the adhesivecoat layer 424 will not be applied. The construction adhesive layer 418is typically a construction adhesive, the adhesive used to attach thevarious components of product into which the microporous film 412 isincorporated. The construction adhesive layer 418 preferably is fromabout 1 gsm to about 7 gsm, more preferably from about 2 gsm to about 5gsm, and most preferably 3.2 gsm. An example of a construction adhesiveis 34-5610 from National Starch and Chemical Company in Bridgewater,N.J.

In another embodiment of the present invention, a breathable microporousfilm 412 can be treated, in accord with the present invention, to createa breathable film having regions of varied breathability usingadhesives. In reference to FIGS. 1a and 1 b, microporous film 412 isunwound from supply roll 414. An adhesive applicator 422, including butnot limited to a Nordson EP45 contact type coating head available fromthe Nordson Corporation at Norcross, Ga., is pulsed to apply an adhesivecoat layer 424 on to areas where less breathability is desired. Theamount of adhesive applied in the adhesive coat layer 424, as well asthe type of adhesive and the type of adhesive application, determinesthe desired reduction in breathability. The adhesive coat layer 424applied to the microporous film 412 at least partially covers or fillsthe pores within the microporous film 412, thereby reducing the size ornumber of pores within microporous film 412 thereby reducing thebreathability of the film in these selected areas. Thus, a breathablemicroporous film 412 can be made having regions of controlledbreathability. As shown in FIGS. 2a and 2 b, a microporous film 412 iscreated having a first breathable regions 426 and second regions 428having a breathability or WVTR lower than that of the first regions 426.The treated film 412 can then be wound on a winder roll 430 or furtherprocessed or converted as desired.

While it may be typical to apply the adhesive coat layer 424 to thebody-side surface 420 of the microporous film 412, the adhesive coatlayer 424 may be applied to the garment-side surface 421 of themicroporous film 412 as it is incorporated into absorbent garments. Thegarment side surface 421 of the microporous film refers to the surfaceof the microporous film 412 that will face away from the wearer, towardthe wearer's clothes when the microporous film 412 is incorporated intothe breathable absorbent garment.

Suitable microporous films for practicing this embodiment of the presentinvention include breathable microporous films having a WVTR of at least800 g/m²/24 hours, and more desirably having a WVTR in excess of 1500g/m²/24 hours, 2500 g/m²/24 hours or 3500 g/m²/24 hours. Desirably, thebreathable microporous film substrate has a WVTR between about 2000g/m²/24 hours and about 7000 g/m²/24 hours. The breathable microporousfilms preferably have a film thickness less than about 100μ (microns)and desirably have a thickness less than about 50μ and more desirablyhave a thickness between about 10 and about 35μ. Thin breathablemicroporous film can be formed by any one of various methods known inthe art. Examples of microporous films suitable for use with the presentinvention include, but are not limited to, those described in thefollowing references. U.S. Pat. No. 5,800,758 issued Sep. 1, 1998 toTopolkaraev et al.; U.S. Pat. No. 4,777,073 issued Oct. 11, 1988, toSheth; and, U.S. Pat. No. 4,867,881 issued Sep. 19, 1989, to Kinzer; theentire contents of the aforesaid references are incorporated herein byreference.

Additional examples of microporous films suitable for use with thepresent invention include, but are not limited to, those described inthe following references: U.S. Pat. No. 4,613,544 issued Sep. 23, 1986,to Burleigh; U.S. Pat. No. 4,833,026 issued May 23, 1989, to Kausch;U.S. Pat. No. 4,863,788 issued Sep. 5, 1989, to Bellairs et al.; U.S.Pat. No. 4,878,974 issued Nov. 7, 1989, to Kagawa; U.S. Pat. No.4,620,956 issued Nov. 4, 1986,to Hamer; U.S. Pat. No. 4,620,955 issuedNov. 4, 1986, to Kono et al.; and, U.S. Pat. No. 5,352,513 issued Oct.4, 1994, to Mrozinski et al.; the entire contents of the aforesaidreferences are incorporated herein by reference.

A preferred breathable microporous film can comprise a stretched-filledfilm which includes a thermoplastic polymer and filler. These (andother) components can be mixed together, heated and then extruded into amonolayer or multilayer film. The filled film may be made by any one ofa variety of film forming processes known in the art such as, forexample, by using either cast or blown film equipment. The thermoplasticpolymer and filler can be stretched in at least one direction, therebyreducing the film gauge or thickness and creating a network ofmicropores throughout the film of a size and frequency to achieve thedesired level of breathability. Such films, prior to stretching,desirably have a basis weight of less than about 100 g/m² and even moredesirably less than about 60 g/m². Upon stretching, the multilayer filmdesirably has a basis weight of less than about 60 g/m² and even moredesirably between about 15 and 35 g/m². Suitable films can also includemultilayer films having at least one microporous layer such as, forexample, those described in the references cited above.

The microporous films can comprise known film forming polymers whichare, by mechanical and/or thermal treatment, permanently deformable.Mechanically deformable polymer films are believed to be suitable foruse with the present invention (e.g. soft rubbers). Desirably themicroporous film is made from a thermoplastic polymer. Preferredthermoplastic polymers used in the microporous films of the presentinvention include, but are not limited to, polyolefins includinghomopolymers, copolymers, terpolymers and blends thereof. Additionalfilm forming polymers suitable for use with the present invention, aloneor in combination with other polymers, include ethylene vinyl acetate,ethylene ethyl acrylate, ethylene acrylic acid, ethylene methylacrylate, ethylene normal butyl acrylate, polyester, polyethyleneterephthalate, polyamides (e.g. nylon), ethylene vinyl alcohol,polystyrene, polyurethane, polybutylene, and polybutylene terephthalate.However, polyolefin polymers are preferred such as, for example,polymers of ethylene and propylene as well as copolymers, terpolymersand blends thereof; examples include, but are not limited to, linear lowdensity polyethylene (LLDPE) and ethylene-propylenecopolymer blends. Themicroporous films can comprise elastic or inelastic polymers. However,with elastic microporous films sufficient energy, e.g. heat and/orpressure, should be imparted to “set” the treated region of the film.

Once the breathable microporous film has been formed, that is the finepore network has been created across the film, the microporous film canbe treated to impart zoned or controlled regional breathability to thefilm. The microporous film can be made in-line or made previously andunwound from a supply roll. Selected regions of the microporous film aretreated with sufficient adhesive to at least partially cover or fill thepores of the film, thereby reducing the number and/or size of porestherein and thereby reduce and/or substantially eliminate thebreathability previously imparted to the film in the treated region. Thebreathability is directly dependent upon the thickness of the adhesive(the amount of adhesive continuity, and percentage of coverage), thetype of adhesive used, and the type of adhesive application used inapplying the adhesive coat layer 424 to the microporous film 412. Thethicker or more uniform the adhesive coat layer 424 applied to themicroporous film 412, the more pores of the microporous film 412 will becovered or filled, thereby reducing the breathability of the microporousfilm 412. Thus, the breathability of the microporous film 412 can bevaried by varying a combination of any or all of the following factors:the thickness of the adhesive coat layer 424 (the amount of adhesivecontinuity and percentage of coverage), the type of adhesive used in theadhesive coat layer 424, and the type of adhesive application used toapply the adhesive coat layer 424 to the microporous film 412.

The treated regions of the film extend at least 3 cm in the CD and MDand more desirably at least 5 cm×5 cm in the CD and MD. Further, thetreated regions of the surface can extend at least 10 cm in either theCD or MD direction. In a further aspect of the invention, the treatedregions desirably comprise from about 5% to about 90% of the area of thefilm. In a preferred embodiment of the present invention the treatedregions comprise a contiguous area comprising from about 5% to about 75%of the area of the overall film and more desirably comprise from about15% to about 60% of the area of the film. In a further embodiment, theregions can comprises a plurality of regions of intermediate and lowbreathability. The regions of low and intermediate breathabilitydesirably form a single contiguous area and which can, in one aspect, bedisposed about the central portion of the film. However, the treatedregions can comprise several non-contiguous regions and needs not becentered on the breathable film 412.

In one embodiment of the present invention, the adhesive coat layer 424can be applied in a continuous pattern as seen in second regions 428 inFIG. 1a. The adhesive coat layer 424 can also be applied such that acontinuous second region 428 is disposed in the center of themicroporous film 412, creating a zoned breathability microporous film412, such as shown in FIGS. 3a and 3 b having highly breathable regions426 adjacent the opposed edges of the film and a central second region428 of reduced breathability therebetween. The reduced breathabilityregion 428 can extend continuously in the machine direction of themicroporous film. In a further aspect of the invention, the thickness(amount or percentage of coverage) of the adhesive coat layer 424 can bevaried in order to further modify the breathability of the correspondingregion of the film. Varying the thickness of the adhesive coat layer 424results in varied levels of breathability extending in the machinedirection.

Varying the thickness (including amount or percentage of coverage by theadhesive coat layer 424) is one method of controlling the breathabilityof the microporous film 412. Other methods include changing the methodof application of the adhesive coat layer 424. For example, a meltblownapplication of 3.2 gsm of adhesive onto the microporous film 412 hasvery little effect on the WVTR of the microporous film 412. However, theslot coating application of 3.2 gsm of adhesive onto the microporousfilm 412 has a marked effect on the WVTR of the microporous film 412.

In a further aspect of the invention, the adhesive coat layer 424 can beapplied so as to create shaped regional breathability to the microporousfilm. In reference to FIGS. 5a and 5 b the adhesive coat layer 424 canbe applied in second regions 428 having different WVTRs. Thus, themicroporous film 412 is thereby created having first region 426 andsecond region 428 wherein first region 426 has a higher WVTR than secondregion 428. The narrow sections, second region 428, can be treated tohave a higher or lower WVTR than wide sections, third region 429.

In a further aspect, the application of the adhesive coat layer 424 canbe discontinuous in the sense that the adhesive is applied in a brokenpattern as shown in FIGS. 4a and 4 b and in FIG. 6. The treatment of amicroporous film 412 as such create first region 426 and second region428 whereby first region 426 has greater breathability than secondregion 428. Further, second region 428 will be separated by portions offirst region 428 in the machine direction.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathability gradient across the CD of the film. Inreference to FIG. 7, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability,second region 428 of low breathability and third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 is thicker (an increased amount or a higher percentageof coverage of the adhesive coat layer 424) than the adhesive coat layer424 applied the third region 429, resulting in a breathability gradient.By varying the thickness of the adhesive coat layer 424 in the CD of themicroporous film 412, a breathability gradient having regions of variedbreathability across the CD of the microporous film 412 is created asopposed to substantially distinct regions of breathability.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathability gradient across the CD of the film. Inreference to FIG. 7, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability,second region 428 of low breathability and third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 is of a different type of adhesive for use in theadhesive coat layer 424 applied in the third region 429, resulting in abreathability gradient. By varying the type of the adhesive coat layer424 in the CD of the microporous film 412, a breathability gradienthaving regions of varied breathability across the CD of the microporousfilm 412 is created as opposed to substantially distinct regions ofbreathability.

As a further example, the adhesive coat layer 424 can be applied in amanner to create a breathabilitygradient across the CD of the film. Inreference to FIG. 7, one such configuration can result in a zonedbreathable film 412 having a first region 426 of high breathability,second region 428 of low breathability and third region 429 ofintermediate breathability. The adhesive coat layer 424 applied in thesecond region 428 under a different method of adhesive application ofthe adhesive coat layer 424 than used to apply the adhesive coat layer424 to the third region 429, resulting in a breathability gradient. Byvarying the type of adhesive application of the adhesive coat layer 424in the CD of the microporous film 412, a breathability gradient havingregions of varied breathability across the CD of the microporous film412 is created as opposed to substantially distinct regions ofbreathability.

The zoned treatment of the microporous film 412 acts to at leastpartially cover or fill the pores of the microporous film 412, therebyreducing the number or size of the pores in the treated regions therebyreducing the WVTR or breathability in those same regions. In referenceto FIGS. 2a and 2 b, the zone treated microporous film can have a firstsubstantially untreated region 426 which has a higher level ofbreathability than the second adhesively treated region 428 of themicroporous film. It is understood that the phrase “substantiallyuntreated region” refers herein to regions that may have undergone atreatment, however the treatment had little or no effect on the WVTR ofthe microporous film 412. The second region 428 will substantiallycorrespond to those areas of the microporous film to which an adhesivecoat layer 424 has been applied.

In a further aspect of the invention, the zoned breathabilitymicroporous film can be joined with one or more additional layers.Alternatively, additional layers can be attached to the microporous filmprior to zone treating the film. Desirably the microporous film isattached to a pliable support layer capable of being laminated to thefilm such as, for example, a pliable fibrous, film and/or foam material.Exemplary fibrous layers include, but are not limited to, nonwoven webs,multilayer nonwoven laminates, scrims, woven fabrics, slit films and/orother like materials. Desirably the support fabric comprises one or morelayers of spunbonded and/or meltblown fiber webs including, but notlimited to, monocomponent spunbond fiber webs, multicomponent spunbondfiber webs, split fiber webs, multilayer nonwoven laminates, bondedcarded webs and the like. Typically, these fibrous layers are highlybreathable and do not impair the breathability of the microporous filmwhen attached to the microporous film. Generally, the composition of thefibrous layer may be selected to achieve the desired properties, i.e.hand, aesthetics, tensile strength, cost, abrasion resistance, hookengagement, etc. It is understood that the bonding means used to attachthe fabric layer to the microporous film should not impair thebreathability of the microporous film. This concern is not as great inareas where reduced WVTR is desired.

Further, the fibrous layer can also be treated such as, for example, byembossing, hydroentangling, mechanically softening, printing or treatedin another manner in order to achieve additional desiredcharacteristics. In one embodiment the outer layer may comprise about a10 g/m² to about 68 g/m² web of spunbonded polyolefin fibers and evenmore desirably a 10 g/m² to about 34 g/m² web of such fibers. Thefibrous layer can be attached or laminated to the microporous film byadhesive bonding, thermal bonding, ultrasonic bonding or other meansknown in the art. In one aspect of the invention the microporous filmand fibrous layer are bonding with an adhesive sprayed via a standardmeltblown die to either the nonwoven fabric and/or film. In a furtheraspect of the invention, the fibrous layer and microporous film can belaminated via thermal point bonding.

The microporous films of the present invention having controlledregional breathability can be used with a wide variety of products or ascomponents of products such as, for example, in personal care articles,infection control products, protective covers, garments and the like. Asa particular example, a microporous film similar to that shown in toFIGS. 2a, 2 b, 3 a, 3 b, 4 a, 4 b, 5 a, 5 b, 6, and 7 can be readilyconverted and incorporated within a breathable barrier of a diaper orincontinence garment whereby the regions of reduced breathability of themicroporous film extend along the central portion or crotch of thediaper. The regions more or less coextensive with the absorbent pad aretypically of lower breathability, while regions typically of higherbreathability extend along the outer portions or “ears” of the garmentwhere the absorbent core is typically not present to maximize dryness orskin health In a further example, the zoned breathability microporousfilms may be used in surgical gowns. It is believed that the regions ofreduced breathability, particularly areas where breathability has beensignificantly or almost completely reduced, may provide improved barrierproperties. For example, areas of reduced breathability are believed toprovide improved barrier properties to blood bome pathogens. Thus,surgical gowns can be fabricated employing the treated or lowbreathability regions within high risk areas, such as the forearms ofthe gown, and higher WVTR regions within lower risk areas. Themicroporous film can also be advantageously utilized in numerous otherapplications employing breathable barrier fabrics.

FIG. 8 shows that the absorbent pad 58 need not cover the entire secondregion 428 and that the absorbent pad 58 may overlap onto a portion ofthe first region 426. Typically the portion of the absorbent pad whichhas the highest aqueous liquid loading is positioned over the secondregion 428. FIG. 9 shows the zone treated microporous film 412 of FIGS.1a and 2 a including an absorbent pad 58 having smaller dimensions thanthe second region 428. FIGS. 4a and 6 show such microporous film 412.FIG. 11 shows an alternate embodiment as shown in FIG. 10 including ashaped backing member 22 and absorbent pad 58 which have leg cutoutstypically included for improved fit and comfort. (See FIGS. 5a and 5 b).However, the size and/or shape of the absorbent pad 58 may coincide withthe size and/or shape of the second region 428.

In some embodiments, the present invention is a method of making a film412 having regions of varied breathability. The method comprises:providing a microporous film 412 wherein said microporous film 412 has ahydrohead of at least 50 mbars and a WVTR of at least 800 g/m²/24 hours;selectively applying adhesive to a portion of said film 412 therebycreating first and second regions 426 and 428 within said film, saidsecond region having dimensions of at least 3 cm by 3 cm wherein theWVTR is decreased within the second region 428 of the film 412 relativeto the WVTR of the first region 426.

Variations of the present invention in other embodiments may include anyof the following: The step of providing the microporous film 412 maycomprise the steps of extruding a film comprising a thermoplasticpolymer and a filler, and stretching said film wherein a plurality ofpores are created throughout said film 412. The application of adhesivemay decrease the WVTR of the second region 428 by at least 25% andfurther wherein the second region 428 has a minimum dimensions of 5 cmby 5 cm. The second region 428 may comprise from about 5% to about 75%of the area of the film 412. The thermoplastic polymer may comprise apolyolefin polymer and wherein the basis weight of each of said firstand second regions 426 and 428 may be below about 35 g/m². The adhesivemay be selectively applied to the microporous film 412 in a coat layer.The second region 428 may comprise between about 5% and 75% of the areaof the film 412 and further wherein the first and second regions 426 and428 of the microporous film 412 each have a basis weight less than about35 g/m². The step of providing the microporous film 412 may furthercomprise the steps of extruding a film comprising a thermoplasticpolymer and a filler and stretching the film 412 wherein said stretchedfilled film may have a basis weight less than about 35 g/m² and a WVTRin excess of 1500 g/m²/24 hours and further wherein the WVTR of thesecond region 428 may be decreased by at least 50%. For example, theadhesive applied to the film 412 may comprise a first thickness and asecond thickness wherein the first region 426, the second region 428,and the third region 429 may be created within the film 412 with thethird region having a WVTR intermediate to the WVTR of the first andsecond regions 426 and 428. The second region 428 may comprise fromabout 5% to about 75% of the film 412. The second region 428 and thethird region 429 may be continuous. The film 412 may have a WVTRgradient. The method may further comprise the step of laminating anonwoven web to the film 412 prior to applying the adhesive.

TEST METHODS

Hydrohead:

A measure of the liquid barrier properties of a fabric is the hydroheadtest. The hydrohead test determines the height of water or amount ofwater pressure (in millibars) that the fabric will support beforeaqueous liquid passes therethrough. A fabric with a higher hydroheadreading indicates it has a greater barrier to aqueous liquid penetrationthan a fabric with a lower hydrohead. The hydrohead can be performedaccording to Federal Test Standard 191A, Method 5514. The hydrohead datacited herein was obtained using a test similar to the aforesaid FederalTest Standard except modified as noted below. The hydrohead wasdetermined using a hydrostatic head tester available from MarlEnterprises, Inc. of Concord, N.C. The specimen is subjected to astandardized water pressure, increased at a constant rate until thefirst sign of leakage appears on the surface of the fabric in threeseparate areas. (Leakage at the edge, adjacent clamps is ignored.)Unsupported fabrics, such as a thin film, are supported to preventpremature rupture of the specimen.

WVTR:

The water vapor transmission rate (WVTR) for the sample materials wascalculated in accordance with ASTM Standard E96-80. Circular samplesmeasuring three inches in diameter were cut from each of the testmaterials and a control which was a piece of CELGARD™ 2500 film fromHoechst Celanese Corporation of Sommerville, N.J. CELGARD™ 2500 film isa microporous polypropylene film. Three samples were prepared for eachmaterial. The test dish was a number 60-1 Vapometerpan distributed byThwing-Albert Instrument Company of Philadelphia, Pa. One hundredmilliliters of water were poured into each Vapometer pan and individualsamples of the test materials and control material were placed acrossthe open tops of the individual pans. Screw-on flanges were tightened toform a seal along the edges of the pan, leaving the associated testmaterial or control material exposed to the ambient atmosphere over a6.5 centimeter diameter circle having an exposed area of approximately33.17 square centimeters. The pans were placed in a forced air oven at100° F. (32° C.) for 1 hour to equilibrate. The oven was a constanttemperature oven with external air circulating through it to preventwater vapor accumulation inside. A suitable forced air oven is, forexample, a Blue M Power-O-Matic 60 oven distributed by Blue M. ElectricCompany of Blue Island, Ill. Upon completion of the equilibration, thepans were removed from the oven, weighed an immediately returned to theoven. After 24 hours, the pans were removed from the oven and weighedagain. The preliminary test water vapor transmission rate values werecalculated with Equation (I) below:

Test WVTR=(grams weight loss over 24 hours)×315.5 g/m²/24 hours   (I)

The relative humidity within the oven was not specifically controlled.

Underthe predetermined set conditions of 100° F. (32° C.) and ambientrelative humidity, the WVTR for the CELGARD™ 2500 control has beendefined to be 5000 grams per square meter for 24 hours. Accordingly, thecontrol sample was run with each test and the preliminary test valueswere corrected to set conditions using Equation (II) below:

WVTR=(Test WVTR/control WVTR)×(5000 g/m²/24 hours)   (II)

Strip Tensile:

The strip tensile test measures the peak and breaking loads and peak andbreak percent elongations of a fabric. This test measures the load(strength) in grams and elongation in percent. In the strip tensiletest, two clamps, each having two jaws with each jaw having a facing incontact with the sample, hold the material in the same plane, usuallyvertically, separated by 3 inches and move apart at a specified rate ofextension. Values for strip tensile strength and strip elongation areobtained using a sample size of 3 inches by 6 inches, with a jaw facingsize of 1 inch high by 3 inches wide, and a constant rate of extensionof 300 mm/min. The Sintech 2 tester, available from the SintechCorporation, 1001 Sheldon Dr., Cary, N.C. 27513, the Instron Model TM,available from the Instron Corporation, 2500 Washington St., Canton,Mass. 02021, or a Thwing-Albert Model INTELLECT II available from theThwing-Albert Instrument Co., 10960 Dutton Rd., Phila., Pa. 19154 may beused for this test. Results are reported as an average of threespecimens and may be performed with the specimen in the cross direction(CD) or the machine direction (MD).

EXAMPLE I

A microporous polyethylene film was laminated to a non-woven fabric toform an outer cover. Adhesive was then added to the film side of theouter cover laminate (which faces the wearer's body when incorporated inan absorbent garment) to create two breathable zones. Adhesive appliedthrough a meltblown application at a level of 3.2 gsm was appliedcontinuously, the full length of the article. A second adhesive head wasused to apply adhesive, generally the length and width of the absorbentcore, through a slot die at the same and higher add-on rates. The firstadhesive system had minimal effect on the film WVTR while the secondsubstantially reduced it. The adhesive used has designation 34-5610 fromNational Starch and Chemical Company in Bridgewater, N.J.

WVTR After WVTR After WVTR After Slot Coated Slot Coated LaminateMeltblown Adhesive Adhesive Applic. Adhesive Applic. WVTR Applic. 3.2gsm 3.2 gsm 6.4 gsm 4,136 3,899 3,087 2,414 4,232 3,933 3,028 2,332(WVTR units g/m2/24 hours)

EXAMPLE II

Referencing the WVTR data in Example I, FIG. 12 shows a breathable filmwith a meltblown adhesive coverage of about 8%. This resulted in theWVTR dropping from about 4200 to about 3900. FIG. 13 shows a breathablefilm with a coat layer coverage of about 24% resulting in about a 1000drop in WVTR. FIG. 14 shows a 70% coat layer coverage which resulted ina WVTR drop of about 1800.

EXAMPLE III

It has been found that slot coating applied to a non-woven web has lesseffect on the laminate WVTR than applying to the film. A slot coater,therefore could be used to maintain high WVTR in the desired productregions if slot coating is applied to a non-woven like fabric ratherthan onto the film.

An equal amount of construction adhesive (34-561 0 from National Starchand Chemical Company in Bridgewater, N.J.) was applied via slot coatingonto both a non-woven fabric (0.75 osy, sheath/core, 50/50 polypropylenepolyethylene spunbond) and a microporous polyethylene film with a WVTRof approximately 4,270. The examples show the smaller reduction in WVTRwhen the non-woven was slot coated compared to when the film wasslot-coated.

Film WVTR Laminate WVTR When Slot Coated onto Non-woven 4,270 4,080Laminate WVTR WVTR When Slot Coated onto Film 4,080 3,500

EXAMPLE IV

It has been found that neither a meltblown (also referred to as MB) norswirl adhesive application lower the WVTR of the microporous filmsignificantly at adhesive levels up to 3.2 gsm of 34-5610 adhesive.

Description WVTR Film 4,266 3.2 gsm MB on nonwoven 4,178 1.6 gsm MB onfilm 4,317 3.2 gsm Swirl on film 4,063 1.0 gsm Swirl on film 4,486

EXAMPLE V

This example demonstrates that high WVTR values can result incondensation of water vapor on the outer surface of an absorbentgarment. This is perceived as leakage by many consumers.

Panelists evaluated the materials in a blind comparison using thefollowing test method. Before evaluation, all samples were loaded with240 ml of body temperature saline, and placed on a heating pad alsowarmed to body temperature for two hours. Each diaper was placed insidea black box for a blind evaluation. All participants evaluated eachmaterial by feeling it four times as presented to them in a randomlyordered sequence. Each material was evaluated independently. Each of thetwo studies included three codes. In each study panelists evaluated atotal of twelve diapers (3 codes×4 repeats=12 diapers) with a fifteenminute break after evaluating six diapers to help reduce hand fatigue.

WVTR of Front Moisture Back Moisture Product Outer Cover Rating Rating A1,650 15.9 22.1 B 2,715 18.8 24.1 C 4,125 20.9 26.3 D 0 12 18 ProductsA, B, C, and D were commercially available diapers in which the outercovers were replaced with over covers having the stated WVTR.

EXAMPLE VI

This example demonstrates that high WVTR levels in nonabsorbent areas ofa disposable garment increase wearer comfort. The disposable garmentstested were commercially available DEPENDS® Undergarments. The test wasconducted on a KES-F7 Thermo-Lobo IIB Type equipment available fromKato-Tech Co., LTD., in Kyoto, Japan. The test method is described inthe operating manual for the equipment. Outer covers of differingbreathability were tested.

The ability of moisture and heat to permeate through fabric is asignificant factor in determining how comfortable a garment will be.Heat can be transferred through a fabric in two ways: dry heat transferand/or moisture-assisted heat transfer. From the dry and wet heattransfer rate measurements, the permeability index (Im), can becalculated. The KES Thermo-labo test measures the dry and wet heattransfer rates of a material using a guarded or sweating hot plate. Italso measures how warm or cool a material feels to the touch and thethermal conductivity of materials.

The characteristic values shown from the KES Thermo-labo test aredescribed below.

Wet Heat Transfer represents the amount of heat that is transferred fromthe skin through the fabric to the outside environment with theassistance of moisture. The larger the wet heat transfer value, the moreheat will be lost or transferred through the fabric with the assistanceof moisture. This test is appropriate for the measurement of heattransfer in most situations where the wearer would perspire.

Im or Permeability Index is the ratio of the thermal and evaporativeresistance of the fabric to the ratio of thermal and evaporativeresistance of air. As the value approaches 1, the less resistant or moreair-like the fabric is. For example, a lightweight, loosely woven fabricwould have a larger Im value than Tyvek. (Differences as small as 0.01can be perceived.)

Non-breathable 1,200 WVTR 2,500 WVTR Woven non- microporous microporous3.5 Cotton microporous film film film osv Wet Heat 7.72 8.87 11.94 18.4Transfer (Watts/m2) IM or 0.18 0.23 0.39 0.59 Permeability Index

EXAMPLE VII

This example demonstrates that high WVTR levels in certain areas of adisposable garment increase wearer skin wellness by reducing skinocclusion and excessive hydration of the skin.

Undergarments that were modifications of commercially available DEPEND®Undergarments, were tested with 20 panelists. The modifications includedshortening the absorbent core from 21 inches to 19 inches (centered onthe outer cover) and incorporating new outer covers with the statedWVTRs. The outer covers consisted of a film (either non-porous ormicroporous) and a nonwoven laminated to the film.

Skin conductance measurements were taken on the panelist's lower back ina region where the garment's body-side liner and outer cover covered theskin (not in a region where the absorbent core was present).

The skin conductance readings were taken with a Skicon 200 instrumentsuch as that available from ACA DERM of Mento Park, Calif. Panelistswere given a short sleeve disposable lab coat, made of polypropylenespunbond, cotton sweatpants, and a pair of cotton underwear to wearduring the test period. Panelists were then allowed to acclimate to theenvironment which was controlled to approximately 72° F./43% R.H. for10-15 minutes. After acclimation, the panelists lay on their stomachs,their clothing over their lower back was peeled down, and a Baselineskin conductance reading was taken using the Skicon.

Subsequently, the panelists were given an undergarment to don, undertheir underwear and sweatpants. The total wear time of the undergarmentwas 1.5 hours. During the first ten minutes of wear time, the panelistsparticipated in a moderate exercise of their choice (such as walking,treadmill, stationary bike, aerobic activity). The next twenty minutes,the panelists rested. They exercised the next ten minutes (3040 minutesinto wear time), rested the next 20 minutes (40-60 minutes intoweartime), exercised the next ten minutes (60-70 minutes into weartime), and finally rested the last twenty minutes of the 1.5 hourundergarment weartime.

After the 1.5 hour wear time, a post-wear skin conductance reading wastaken in the same manner and region as the baseline reading.

The change in skin conductance, from the baseline to post wear regions,represents the change in skin hydration during that period. The datashows that the non-breathable product resulted in a much greaterincrease in skin hydration than the breathable products. Such increasesover time lead to wearer discomfort and reduced skin wellness.

Change in Skin Baseline Skin Post wear Skin Surface Moisture SurfaceMoisture Surface Moisture Reading after Reading Reading Wear TimeNon-breathable 220 1,187 967 non-micropor- ous film 2,500 WVTR 222 376154 microporous film 3,700 WVTR 239 364 125 microporous film

While various patents and other reference materials have beenincorporated herein by reference, to the extent there is anyinconsistency between incorporated material and that of the writtenspecification, the written specification shall control. In addition,while the invention has been described in detail with respect tospecific embodiments thereof, it will be apparent to those skilled inthe art that various alterations, modifications and other changes may bemade to the invention without departing from the spirit and scope of thepresent invention. It is therefore intended that the claims cover allsuch modifications, alterations and other changes encompassed by theappended claims.

What is claimed is:
 1. A method of making a film having regions ofvaried breathability comprising: providing a microporous film whereinsaid microporous film has a hydrohead of at least 50 mbars and a WVTR ofat least 800 g/m²/24 hours; selectively applying adhesive to a portionof said film thereby creating first and second regions within said film,said second region having dimensions of at least 3 cm by 3 cm andwherein the porosity and the WVTR is decreased within said second regionof the film relative to the WVTR of the first region.
 2. The method ofclaim 1 wherein providing said microporous film comprises the steps ofextruding a film comprising a thermoplastic polymer and a filler andstretching said film wherein a plurality of pores are created throughoutsaid film.
 3. The method of claim 2 wherein the application of adhesivedecreases the WVTR of the second region by at least 25% and furtherwherein said second region has a minimum dimensions of 5 cm by 5 cm. 4.The method of claim 3 wherein said second region comprises from about 5%to about 75% of the area of said film.
 5. The method of claim 4 whereinsaid thermoplastic polymer comprises a polyolefin polymer and whereinthe basis weight of each of said first and second regions is below about35 g/m².
 6. The method of claim 1 wherein said adhesive is selectivelyapplied to said microporous film in a coat layer.
 7. The method of claim6 wherein said second region comprises between about 5% and 75% of thearea of said film and further wherein said first and second regions ofsaid microporous film each have a basis weight less than about 35 g/m².8. The method of claim 7 wherein providing said microporous filmcomprises the steps of extruding a film comprising a thermoplasticpolymer and a filler and stretching said film wherein said stretchedfilled film has a basis weight less than about 35 g/m² and a WVTR inexcess of 1500 g/m²/24 hours and further wherein said WVTR of saidsecond region is decreased by at least 50%.
 9. The method of claim 1wherein said adhesive applied to said film comprises a first thicknessand a second thickness wherein first, second, and third regions arecreated within said film with said third region having a WVTRintermediate to the WVTR of said first and second regions.
 10. Themethod of claim 9 wherein said second region comprises from about 5% toabout 75% of said film.
 11. The method of claim 10 wherein said secondand third regions are continuous.
 12. The method of claim 11 whereinsaid film has a WVTR gradient.
 13. The method of claim 4 furthercomprising the step of laminating a nonwoven web to said film prior toapplying said adhesive.